Impregnated alumina-containing material

ABSTRACT

A composition of matter is prepared by a process comprising the steps of impregnating a alumina-containing support material with a thiosulfate (preferably ammonium thiosulfate), drying the thus impregnated material, impregnating the dried material with a transition metal compound, drying and calcining the transition metal impregnated material. This composition of matter is used as catalyst composition for hydrogenating unsaturated hydrocarbon compounds, and as catalyst composition for hydrotreating hydrocarbon-containing feed streams (in particular heavy oils) which contain metal and sulfur compounds as impurities. 
     In another embodiment, a hydrotreating process comprises contacting hydrocarbon-containing feed stream (in particular heavy oils), which contains compounds of sulfur and metals, in the presence of a fixed catalyst bed comprising (X) at least one layer of impregnated substantially spherical alumina-containing particles, which have been prepared by a process comprising the steps of impregnating a specific starting material with (NH 4 ) 2  S 2  O 3  and then heating the thus impregnated material at about 500°-900° C. for improved crush strength retention. In a preferred embodiment, the fixed catalyst bed further comprises at least one layer (Y) of catalyst particles comprising a refractory inorganic carrier and at least one hydrogenation promoter. A composition of matter comprising the impregnated, spherical alumina-containing particles described above, and a process for preparing them are also provided.

This application is a division of Ser. No. 052,097; filed May 20, 1987;now U.S. Pat. No. 4,778,588.

BACKGROUND OF THE INVENTION

In one aspect, this invention relates to catalytic hydrotreating ofliquid hydrocarbon-containing feed stream, in particular heavy petroleumfractions. In another aspect, this invention relates to catalytichydrogenation of unsaturated hydrocarbons. In a further aspect, thisinvention relates to new compositions of matter, suitable as catalystsfor hydrotreating and hydrogenation reactions.

The use of alumina, either umpromoted or promoted with transition metalcompounds, for hydrotreating (e.g., demetallizing, desulfurizing,denitrogenating, hydrocracking, hydrogenating) liquid hydrocarbon feedstreams, which contain metal, sulfur and nitrogen impurities, is wellknown. The removal of these impurities is desirable because they canpoison catalysts in downstream operations such as catalytic cracking,and can cause pollution problems when hydrocarbon products from thesefeed streams are used as fuels in combustion processes. It is also knownto use alumina-supported transition metal catalysts for hydrogenation ofunsaturated hydrocarbons (such as olefins or cycloolefins). However,there is an ever present need to develop new alumina-containingmaterials having improved hydrotreating/hydrogenating activity and/orhaving other improved properties, such as higher crush strength.

SUMMARY OF THE INVENTION

It is an object of this invention to provide effective hydrotreatingcatalyst compositions. It is another object of this invention to provideprocesses for preparing new effective hydrotreating catalystcompositions. It is still another objective of this invention, toprovide a process for hydrogenating unsaturated hydrocarbons in thepresence of a new, effective catalyst composition. It is a still furtherobject of this invention to provide hydrotreating processes for theremoval of sulfur, nickel, vanadium and other impurities fromhydrocarbon-containing oils, in the presence of new effectivehydrotreating catalyst compositions. Other objects and advantages willbe apparent from the detailed description and the appended claims.

In accordance with this invention, there are provided a process and acomposition of matter (suitable as a catalyst composition) comprisingalumina and at least one compound of at least one transition metalbelonging to Groups VIB, VIIB, VIII or IB of the Periodic Table (asdefined in Webster's Collegiate Dictionary, 1977), said composition ofmatter being prepared by the process comprising the steps of:

(A) impregnating a support material comprising (preferably consistingessentially of) alumina with a solution comprising (preferablyconsisting essentially of) water and at least one dissolved thiosulfateand/or compound (preferably Group IA and/or Group IIA metal thiosulfateand/or ammonium thiosulfate; more preferably (NH₄)₂ S₂ O₃);

(B) heating the material obtained in step (A) under such conditions asto at least partially dry said material obtained in step (A);

(C) impregnating the at least partially dried material obtained in step(B) with a solution comprising (preferably consisting essentially of) aliquid solvent (preferably water) and at least one dissolved compound ofat least one metal selected from the group consisting of transitionmetals belonging to Group VB, Group VIB, Group VIIB, Group VIII andGroup IB of the Periodic Table of Elements (preferably at least of Mo,Ni and Co);

(D) heating the material obtained in step (C) at a first temperature soas to at least partially dry said material obtained in step (C);

(E) heating (i.e., calcining) the at least partially dried materialobtained in step (D) at a second temperature, which is higher than saidfirst temperature, so as to activate said at least partially driedmaterial obtained in step (D).

Also in accordance with this invention, a feed stream which comprises atleast one unsaturated hydrocarbon compound (preferably alkene,cycloalkene, alkadiene; cycloalkadiene, alkatriene, cycloalkatriene,alkyne) is contacted with a free hydrogen-containing gas (preferablysubstantially pure H₂) and the composition of matter (catalystcomposition) prepared by the process comprising steps (A) through (E),under such hydrogenating conditions as to obtain a product streamcomprising at least one product compound containing more hydrogen thansaid at least one unsaturated hydrocarbon compound from which it isformed.

Further in accordance with this invention, a substantially liquid (i.e.,liquid at the hydrotreating conditions) hydrocarbon-containing feedstream, which also contains compounds of at least one metal (preferablynickel and/or vanadium) and of sulfur as impurities, is simultaneouslycontacted with a free hydrogen-containing gas (preferably consistingessentially of H₂) and the composition of matter prepared by the processcomprising steps (A) through (E), under such hydrotreating conditions asto produce a hydrocarbon-containing stream having reduced levels ofmetal and sulfur.

Still further in accordance with this invention, there are provided aprocess and a composition of matter (suitable as a material for a layerin a fixed hydrotreating bed) comprising (preferably consistingessentially of) impregnated, substantially spherical alumina-containingparticles, prepared by the process comprising the steps of:

(a) impregnating (i) a starting material of substantially sphericalalumina-containing particles which have an initial average particle size(diameter) of at least about 0.05 inch, an initial surface area(determined by the BET/N₂ method; ASTM D3037) of at least about 20 m²/g, an initial pore volume (determined by mercury intrusion porosimetryat a pressure ranging from 0 to 50,000 psig) of at least about 0.1 cc/g,and an initial Al₂ O₃ content of at least about 80 weight-%, with (ii) asolution (preferably aqueous) comprising dissolved ammonium thiosulfate;and

(b) heating the material obtained in step (a) at a temperature in therange of from about 500° to about 900° C. for a period of time of atleast about 10 minutes (preferably in the range of from about 10 minutesto 20 hours), under such heating conditions as to obtain a materialhaving a higher crush strength than said starting material (wherein thecrush strength is measured after exposure of each of the two materialsfor about 100 hours to a liquid hydrocarbon-containing stream whichcontains at least about 0.5 weight-% sulfur, under hydrotreatingconditions at about 2250 psig total pressure, about 400 psig partialpressure of steam and about 700° F.).

Preferably a drying step (a1) after step (a) is carried out, so as toremove at least a portion of water from the material obtained in step(a). In this preferred embodiment, step (b) is carried out with thematerial obtained in step (a1). Also preferably, the starting materialused in step (a) has a normalized crush strength of at least about 100lb per inch diameter per particle, and an initial Na content of lessthan about 3.0 weight-%.

Still further in accordance with this invention, a hydrotreating processis provided wherein a substantially liquid hydrocarbon containing feedstream, which also contains compounds of at least one metal (preferablyNi and/or V) and of sulfur as impurities, is simultaneously contactedwith a free hydrogen containing gas (preferably substantially pure H₂)and a fixed catalyst bed comprising (Y) at least one layer of thecomposition of matter prepared by the process comprising steps (a) and(b), and optionally also (a1), under such hydrotreating conditions as toproduce a hydrocarbon-containing stream having reduced levels of metal(preferably Ni and/or V) and sulfur.

In a particularly preferred embodiment, said fixed catalyst bedadditionally comprises (Y) at least one layer of catalyst particles[i.e., hydrotreating catalyst particles; different from the particles inlayer (X)] comprising a refractory inorganic carrier (preferablyalumina) and at least one (i.e., one or a mixture of two or more)hydrogenation promoter selected from the group consisting of transitionmetals of Groups IIIB, IVB, VB, VIB, VIIB, VIII, IB and IIB of thePeriodic Table (as defined in Webster's New Collegiate Dictionary, 1977)and compounds of these metals (preferably Y, La, Ce, Ti, Zr, Cr, Mo, W,Mn, Re, Ni, Co and Cu, and compounds thereof).

In another preferred embodiment of this invention, a fixed catalyst bed(preferably a hydrotreating catalyst bed) is provided comprising

(X) at least one catalyst bed layer of impregnated, substantiallyspherical alumina-containing particles of this invention, having beenprepared by the process composing steps (a) and (b), and optionally alsostep (a1), as described above; and

(Y) at least one catalyst bed layer of catalyst particles [preferablyhydrotreating catalyst particles; different from the particles in layer(X)] comprising a refractory inorganic carrier material and ahydrogenation promoter, as defined immediately above.

In a further preferred embodiment of this invention, said impregnated,substantially spherical alumina-containing particles, which can be usedin catalyst bed layer (X), also contain at least one compound of atleast one element selected from the group consisting of Y, La, Ce, Ti,Zr, Cr, Mo, W, Mn, Re, Ni, Co, Cu, Zn and P, preferably oxide and/orsulfide of Mo and/or Co and/or Ni (more preferably containing about0.1-2.0 weight-% Mo) as hydrotreating promoters. In a more preferredembodiment, the impregnating solution used in step (a) comprises atleast one compound of at least one of the elements listed immediatelyabove.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows the arrangement of a fixed multi-layer catalyst bed usedfor testing catalysts in hydrotreating processes.

FIG. 2 is a graph showing the dependence of crush strength (determinedafter use in a hydrotreating test in the presence of steam) ofimpregnated alumina-containing particles on the (NH₄)₂ S₂ O₃concentration in the impregnating solution.

FIG. 3 is a graph showing the dependence of crush strength (determinedafter use in a hydrotreating test in the presence of steam) ofalumina-containing particles on the calcination temperature.

FIG. 4 exhibits pore distribution curves for several alumina-containingparticles.

DETAILED DESCRIPTION OF THE INVENTION Composition Prepared by ProcessComprising Steps (A) Through (E).

The alumina support material used in step (A) of the preparation of thecomposition of matter (catalyst composition) of this invention can beany alumina or partially hydrated forms thereof, preferablysubstantially pure alumina. Generally, the surface area (determined bythe BET/N₂ method; ASTM D3037) of said support material is about 20 toabout 350 m² /g and the pore volume (measured by mercury intrusionporosimetry) is about 0.2 to about 2.0 cc/g. The support material maycontain transition metals such as those of Groups IB, IIB, IIIB, IVB,VB, VIB, VIIB and VIII of the Periodic Table, e.g., Mo, Ni, Co orcompounds thereof. At present, it is not preferred to have more thanonly traces of these transition metals present in the alumina-containingsupport material i.e., the level of these transition metals should beless than about 0.2 weight-%, based on the weight of the entirealumina-containing material (before impregnation).

It is within the scope of this invention (yet presently not preferred)to employ mixtures of alumina with other inorganic refractory materialssuch as silica, aluminosilicates (such as zeolites), magnesia, titania,zirconia, aluminum phosphate, zirconium phosphate, alumina-silica,alumina-titania, zeolite-alumina, zeolite-silica and the like.Generally, the above-mentioned other refractory materials will notexceed about 10 weight-%, based on the weight of the alumina-containingsupport material. The alumina support material can be spherical(presently preferred diameter of alumina particles: about 0.2-20 mm,preferably about 0.5-3 mm) or can have cyclindrical, trilobal orquadtrilobal form or can be irregularly shaped.

Any suitable thiosulfate compound can be used as solute in the solutionemployed in step (A). Non-limiting examples of such thiosulfates are(NH₄)₂ S₂ O₃, NaHS₂ O₃, Na₂ S₂ and other alkali metal thiosulfates, MgS₂O₃, CaS₂ O₃ and other alkaline earth metal thiosulfates, preferably(NH₄)₂ S₂ O₃. It is understood that these thiosulfates can be applied ashydrates. It is also understood that the ammonium group in ammoniumthiosulfate can be alkyl-substituted (presently not preferred).

The concentration of the thiosulfate compound in the aqueousimpregnating solution used in steps (A) generally is in the range offrom about 1 to about 200 grams per liter (g/l) solution, preferablyfrom about 10 to about 100 g/l, more preferably from about 30 to about80 g/l. The weight ratio of the alumina-containing support material tothe thiosulfate-containing impregnating solution employed in steps (A)generally is in the range of from about 1:20 to about 5:1 (depending onthe concentration of the thiosulfate-containing solution), preferablyfrom about 1:5 to about 1:1. The impregnation time in step (A) should belong enough to ensure that the alumina-containing support materials aresubstantially penetrated by the impregating solution. Generally, theimpregnation time is in the range of from about 0.5 to about 60 minutes,preferably from about 1 to about 10 minutes. The temperature duringimpregnation in step A can be ambient (e.g., about 60°-75° F.) or higher(e.g., about 80°-200° F.).

Heating steps (b) and (D) are generally carried out in an oxidizing gasatmosphere (preferably in air) or an inert gas atmosphere, at atemperature ranging from about 40° C. to about 300° C. so as to removethe greatest portion of water from the mixture obtained in the precedingstep. The preferred temperature for step (B) is in the range of fromabout 80° C. to about 300° C.; the preferred temperature for step (D) isin the range of from about 50° C. to about 200° C. Vacuum conditions maybe employed but are presently not preferred. The substantially driedmaterial obtained in step (B) generally contains less than about 5weight-% water. The at least partially dried material obtained in step(D) generally contains less than 20 weight-% water. The rate of heatingis controlled so as to avoid surges of water vapor that can cause theimpregnating solution to splatter and to excessively accumulate incertain surface regions of the solid support material. Depending on theheating temperature and specific heating conditions (such as extent ofgas movement and thickness of the solid layer to be dried), the heatingtime ranges generally from about 0.5 hour to about 100 hours, preferablyfrom about 1 hour to about 30 hours.

Impregnating step (C) can be carried out in any suitable manner with anysuitable dissolved transition metal compound that is at least partiallysoluble in the solvent of the solution. The solvent can be an organicsolvent such as methanol, ethanol, higher alcohols, carboxylic acidssuch as acetic acid, acetone, esters and similar polar liquids.Preferably the solvent is water. Non-limitative examples of metalscontained in said dissolved metal compound are Cr, Mo, W, Re, Co, Ni, Cuand mixtures of two or more; preferably Mo, Co, Ni and mixtures of twoor three of these metals. The transition metal compounds can be halides(e.g., chlorides), nitrates, sulfates, bisulfates, bicarbonates,carboxylates (e.g., acetate, oxalate, citrate and the like),coordination complexes (e.g, amino complexes of Ni and Co salts and thelike), homoand hetropolyacids and their salts (e.g., ammoniummolybdates), and the like. It is understood that these compound can beapplied as hydrates, e.g., Ni(NO₃)₃ ·6H₂ O, Co(NO₃)₃ ·6H₂ O and (NH₄)₂Mo₇ O₂₄ ·4H₂ O (all three compounds being presently preferred).

Any suitable concentration of the at least one transition metal compoundin the impregating solution of steps (C) and any suitable weight ratioof the at least partially dried material from step (B) to saidimpregating solution can be applied. This concentration and weight ratiocan vary widely, depending on what the desired level of transition metalpromoter in the finished catalyst composition is. Generally the combinedconcentration of all metal compounds in the impregnating solution ofstep (C) is in the range of from about 0.01 to about 5.0 mol/l,preferably from about 0.05 to about 3.0 mol/l. The weight ratio of theat least partially dried material obtained in step (B) to theimpregnating solution generally is in the range of from about 1:100 toabout 10:1, preferably from about 1:10 to about 2:1. Other solvents(which may aid in the dissolving of the metal compounds) such as acids(e.g., citric acid, phosphoric acid), borates and phosphates may also bepresent in the impregnating solution.

Step (C) can be carried out at room temperature (e.g., 60°-75° F.) as atelevated temperatures (e.g., 80°-200° F.), with or without agitation.The at least partially dried material obtained in steps (B) can besoaked with the impregnating solution (with or without agitation) or canbe mixed for any suitable time (generally about 1 minute to about 5hours, preferably about 0.1-2 hours). Excess impregnating solution canbe drained. The impregnating solution can also be sprayed onto the atleast partially dried material from step (B). Presently, soaking of thematerial obtained in step (B) with the impregnating solution andsubsequent draining of excess solution is preferred.

Even though it is preferred to employ substantially clear aqueoussolutions in steps (A) and (C), it is within the scope of this inventionto use aqueous solutions having solid particles dispersed therein. Inthis case, the solutions plus dispersed particles can be used "as is" insteps (A) and (C), or, preferably, the dispersed solid particles areseparated from the solutions by any suitable separation means, such asfiltration, centrifugation or settling and subsequent draining, beforethe solutions are used for the impregnation of alumina.

The preferred heating (calcining) conditions in step (E) compriseheating in a non-reducing gas atmosphere, a temperature ranging fromabout 300° C. to about 700° C. (more preferably from about 400° C. toabout 600° C.) and a heating time ranging from about 1 to about 10hours. Presently preferred specific calcining conditions are describedin Example I (Catalyst A). Generally, the heating is carried out in afree oxygen containing atmosphere, preferably air. But othernon-reducing gases, e.g., nitrogen, helium, neon, argon, krypton, xenonor mixtures thereof, may also be employed.

The terms "activate" and "activation" as used herein means that thecalcined catalyst composition of this invention is a more effectivecatalyst for either the hydrogenation of unsaturated hydrocarboncompounds and/or for hydrotreating reactions, particularlyhydrodemetallization and hydrodesulfurization of liquidhydrocarbon-containing feed streams, than the at least partially driedmixture obtained in preceding step (D). Preferably transition metalcompounds contained in the at least partially dried material obtained instep (D) are at least partially converted to metal oxides in step (E).

The calcined composition of matter of this invention obtained in step(E) generally contains from about 0.1 to about 25 weight-% transitionmetal, and preferably contains from about 0.3 to about 8.0 weight-%transmition metal. The surface area (determined by the BET/N₂ method;ASTM D3037) of the calcined catalyst compositions of matter of thisinvention generally is in the range of from about 20 to about 350 m² /g,preferably in the range of from about 100 to about 250 m² /g. The porevolume (determined by mercury intrusion using an Autopore 9200instrument of Micromeretics, Norcross, Georgia) generally is in therange of from about 0.2 to about 2.0 cc/g. The compositions of matter ofthis invention can be spherical or can be compacted into various shapes(e.g., cylindrical, trilobal etc) for convenient shipping and use infixed catalyst beds.

In one embodiment, the composition of matter (catalyst composition) ofthis invention obtained in step (E) is presulfided by the additionalstep (F) of contacting the calcined compositions of matter with at leastone suitable sulfur compound under such conditions as to at leastpartially convert transition metal compounds (preferably oxides)contained in the calcined catalyst composition to transition metalsulfides. This can be accomplished by passing a sulfur-containing oil(preferably gas oil) or solutions of COS or of mercaptans or of organicsulfides, e.g., in hydrocarbon solvents, over the composition of matterat an elevated temperature (e.g., at about 300°-650° F.), generally inthe presence of hydrogen gas; or a gaseous mixture of hydrogen andhydrogen sulfide (e.g. at a volume ratio of about 10:1) can be passedover the catalyst composition at an elevated temperature, preferably1-15 hours at about 400° F. and then 1-15 hours at about 700° F. Thispresulfiding step is particularly desirable when the composition ofmatter (catalyst composition) of this invention is used forhydrotreating or hydrocracking of liquid hydrocarbon-containing feedstreams.

The composition of matter obtained in step (E) can also be heated in areducing gas such as H₂, CO, methane and the like or gas mixturescontaining H₂, CO, methane and the like, under such conditions as to atleast partially (preferably substantially) convert transition metalcompounds to the metallic form (e.g., Ni metal). The reducing treatmentis preferably carried before the hydrogenation of unsaturatedhydrocarbon compounds.

Hydrogenation of Unsaturated Hydrocarbon Compounds

Any suitable unsaturated hydrocarbon compound possessing at least oneC═C double bond (i.e., one, two or more than two C═C bonds), or at leastone C═C triple bond, or both C═C and C═C bonds can be used as theunsaturated hydrocarbon feed compound in the hydrogenation process ofthis invention, employing the catalyst composition prepared by theprocess comprising steps (A) through (E).

The unsaturated hydrocarbon feed compound can be any suitablestraight-chain or branched alkene (monolefin), preferably containing2-12 carbon atoms per molecule and preferably being either gaseous orliquid at ambient conditions (about 20° C., 1 atm). Non-limitingexamples of suitable alkenes are ethylene, propylene, 1-butene,2-butene, 1-pentene, 2-pentene, 2-methyl-1-butene, 3-methyl-1-butene,1-hexene, 4-methyl-1-pentene, 2,3-dimethyl-1-butene, 2-ethyl-2-butene,heptenes, octene, nonenes, decenes, undecenes, dodecenes, mixturesthereof.

The unsatured hydrocarbon feed compound can be any suitablestraight-chain or alkyl-substituted cycloalkene (cyclomonoolefin),preferably containing 5-12 carbon atoms per molecule and preferablybeing liquid at ambient conditions. Non-limiting examples ofcycloalkenes are cyclopentene, methylcyclopentenes, cyclohexenes,methylcyclohexenes, ethylcyclohexenes, cycloheptenes, cyclooctenes, andcyclononenes, and mixtures thereof. Presently preferred is cyclohexene.

The unsaturated hydrocarbon feed compound can be any suitablestraight-chain or branched alkyne (acetylene), preferably containing2-12 carbon atoms per molecule and preferably being gaseous or liquid atambient conditions. Non-limiting examples of suitable alkynes are:acetylene, 1-propyne, 1-butyne, 2-butyne, 1-pentyne, 2-methyl-1-butyne,hexynes, heptynes, octynes, nonynes, decynes and mixtures thereof.

The unsaturated hydrocarbon feed compound can be any suitableunsubstituted or alkyl-substituted alkadiene (diolefin), alkatriene(triolefin), cycloalkadiene (cyclodiolefin) and cycloalkatriene(cyclotriolefin), preferably those disclosed in U.S. Pat. No. 4,570,025,herein incorporated by reference.

It is understood that the feed stream may contain any mixture of two ormore unsaturated hydrocarbon compounds, such as mixtures of alkenes andcycloalkenes, alkenes and alkadienes, cycloalkenes and cycloalkadienesand the like. It is also understood that the unsaturated hydrocarboncompound can contain substituents such as halogen, hydroxyl group,aldehyde group, carboxyl group, ether group, ester group, phenyl group,alkyl-phenyl groups and the like, as long as these substituents do notadversely affect the hydrogenation process of this invention. Presentlythese substituents are not preferred.

The feed stream containing at least one unsaturated hydrocarboncompound, the hydrogen containing gas stream and the catalystcomposition of this invention [prepared by the process comprising steps(A) through (E)] can be contacted in any suitable manner in thehydrogenation process of this invention. Said two streams can be addedseparately into a suitable reaction vessel and then contacted in atleast partially mixed form with the catalyst composition under suitablereaction (hydrogenating) conditions. Or the two streams can be premixedand then contacted with the catalyst composition under suitablehydrogenation conditions so as to produce a reaction product comprisingat least one compound containing fewer C═C and/or C═C bonds than thefeed hydrocarbon compound or, alternatively, no C═C and/or C═C bonds atall.

The hydrogenting process of this invention can be conducted as a batchprocess or an a continuous process. In a batch process, the processingredients are added in any order to a reaction vessel, preferablyequipped with agitating and heating means, and the process ingredientsare then kept in contact with each other for a certain length of timeand under suitable reaction (hydrogenating) conditions so as to producea product being less unsaturated than the feed or, alternatively, beingsaturated. In this type of operation, the catalyst can be dispersed inthe hydrocarbon containing feed (preferably liquid) and contacted with afree hydrogen containing gas with agitation (e.g., by means of amechanical mixer or static mixing means); or the feed and the freehydrogen containing gas can be circulated through a fixed bed containingthe catalyst composition. In a continuous process, which is presentlypreferred, the unsaturated hydrocarbon-containing feed stream(preferably liquid) and the free hydrogen containing gas stream can bepassed, at least partially mixed, through a fixed bed containing thesolid hydrogenation catalyst composition of this invention, under suchconditions as will result in a product, as defined above. Optionally, aninert solvent can be present during the batch or continuous process.

Heating of the process ingredients can be such as to accomplish at leastpartial conversion (preferably exceeding 50%) of the feed. Any suitabletemperature that will cause and maintain a controllable reaction can beemployed. Any feasible heating means, if necessary, can be utilized. Itis within the scope of this invention to preheat one or more of theprocess ingredients before they are introduced into a reactor. Thereaction temperature generally exceeds about 80° C. and preferablyranges from about 100° C. to about 300° C., more preferably from about150° C. to about 250° C.

The total reaction pressure can be atmospheric (about 15 psia) orhigher. The selection of the reaction pressure will greatly depend onthe reaction temperature, the feed rates of the liquid feed stream andthe hydrogen gas stream, and the specific reactor design. Generally, thetotal reaction pressure ranges from about 15 to about 5000 psia,preferably about 15 to about 1000 psia, more preferably from about 100to about 300 psia. Preferably, the reaction pressure is high enough soas to keep the hydrocarbon containing feed stream substantially in theliquid phase.

The reaction time, i.e., the time of intimate, simultaneous contact ofall required process ingredients (including catalyst composition), canvary from 1 minute to about 50 hours and will preferably be in the rangeof about 0.2 to about 1 hours. The actual reaction time will greatlydepend on the flow rate of the hydrocarbon feed stream, the flow rate ofthe free hydrogen containing gas stream, the selection of an effective(yet safe) reaction temperature, the extent of mixing and agitation (ifany) during the reaction, and the amount of the catalyst employed.

Any suitable molar ratio of hydrogen to unsaturated feed hydrocarbon canbe employed. The amount of hydrogen charged to the reactor is chosen soas to initiate and maintain a suitable, safe rate of reaction underspecific reaction conditions. The mol ratio of initially chargedhydrogen to the unsaturated feed hydrocarbon (alkene, alkadiene,alkatriene, alkyne, cycloalkene, cycloalkadiene or cycloalkatriene) canvary over a wide range, such as about 0.05:1 to about 200:1, but willtypically be in the range of about 5:1 to about 20:1 in a continuousflow system.

The formed reaction products can be recovered for the reaction mixture,and the hydrocarbon product compounds can be separated from each otherby any suitable separation means such as fractional distillation,crystallization, extraction with a suitable solvent, and the like.Unreacted process ingredients can be recycled to the reaction zone withadded fresh process ingredients. It is generally expected that alkenesare substantially converted to alkanes, cycloalkenes to cycloalkanes,alkadienes to alkenes, cycloalkadienes to cycloalkenes, alkynes toalkenes and/or alkane and the like. Preferably, in the hydrogenationprocess of this invention, cyclohexene is substantially converted tocycloahexane.

Hydrotreating Process

The composition of matter of this invention can be used as a catalystcomposition for a variety of hydrocarbon conversion reactions. In onepreferred embodiment of this invention, the catalyst composition of thisinvention is used as a catalyst for hydrotreating substantially liquidhydrocarbon-containing feed streams, which also contain compounds ofsulfur, nickel and/or vanadium as impurities, and generally alsoasphaltenes, coke precursors (measured as Ramsbottom carbon residue) andnitrogen compounds. Suitable hydrocarbon containing feed streams includecrude oil and heavy fraction thereof, heavy oil extracts, liquid coalpyrolyzates, heavy liquids from coal liquification, heavy liquidsobtained from tar sands, shale oil and heavy shale oil fractions. Thecatalyst compositions are particularly suited for treating heavy oilresidua, which generally have an initial boiling point in excess ofabout 400° F., preferably in excess of about 600° F., contain about5-1000 ppmw (parts by weight per million by weight of feed stream) ofvanadium, about 3-500 ppmw of nickel, about 0.3-5 weight-% sulfur andabout 0.2-2 weight-% nitrogen, and have an API₆₀ gravity of about 5-30.

The hydrotreating process of this invention employing the catalystcomposition of this invention is carried out in any apparatus wherein anintimate contact of the catalyst composition with saidhydrocarbon-containing feed stream and a free hydrogen containing gas isachieved, under such conditions as to produce a hydrocarbon-containingproduct having a reduced levels of nickel and/or vanadium and sulfur.Generally, a lower level of nitrogen and Ramsbottom carbon residue and ahigher value of API₆₀ gravity are also attained in this hydrotreatingprocess. The hydrotreating process can be carried out using a fixedcatalyst bed (presently preferred) or a fluidized catalyst bed or amoving catalyst bed or an agitated slurry of the catalyst in the oilfeed (hydrovisbreaking operation). The hydrotreating process can becarried out as a batch process or, preferably, as a continuous process,more preferably in a tubular reactor containing one or more fixedcatalyst beds or in a plurality of fixed bed reactors in parallel or inseries.

The catayst composition of this invention can be used in saidhydrotreating process alone in a reactor or may be used in combinationwith essentially unpromoted refractory materials such as alumina,silica, titania, magnesia, silicates, metal aluminates,alumino-silicates (e.g., zeolites), metal phosphates and mixtures ofthese materials. Alternating layers of the refractory material and ofthe catalyst composition can be used, or the catalyst composition can bemixed with the refractory material. Use of the refractory material withthe catalyst composition provides for better dispersion of thehydrocarbon-containing feed stream. Also, other catalysts such as knownhydrogenation and desulfurization catalysts (e.g., NiO/MoO₃, CoO/MoO₃and NiO/CoO/MoO₃ on silica or titania) may be used with the catalystcomposition of this invention to achieve simultaneous demetallization,desulfurization, denitrogenation, hydrogenation and hydrocracking, ifdesired. In one embodiment of said hydrocarbon hydrotreating process,the catalyst composition has been presulfided, as described above,before being used.

Any suitable contact (reaction) time between the catalyst composition,the hydrocarbon-containing feed stream and hydrogen gas can be utilized.In general, the reaction time will range from about 0.05 hours to about10 hours. Preferably, the reaction time will range from about 0.4 toabout 5 hours. Thus, the flow rate of the hydrocarbon-containing feedstream should be such that the time required for the passage of themixture through the reactor (residence time) will preferably be in therange of about 0.4 to about 5 hours. In a continuous fixed bedoperation, this generally requires a liquid hourly space velocity (LHSV)in the range of about 0.10 to about 20 cc of feed per cc of catalyst perhour, preferably from about 0.2 to about 2.5 cc/cc/hr.

The hydrotreating process employing the catalyst composition of thepresent invention can be carried out at any suitable temperature. Thetemperature will generally be in the range of about 250° C. to about550° C. and will preferably be in the range of about 350° C. to about450° C. Higher temperatures do improve the removal of metals, buttemperatures which will have adverse effects on thehydrocarbon-containing feed stream, such as excessive coking, willusually be avoided. Lower temperatures can generally be used for lighterfeeds.

Any suitable pressure may be utilized in the hydrotreating process ofthis invention. The reaction pressure will generally be in the range ofabout atmospheric pressure (0 psig) to up to about 5,000 psig.Preferably, the pressure will be in the range of about 100 to about 2500psig. Higher pressures tend to reduce coke formation but operating athigh pressure may be undesirable for safety and economic reasons.

Any suitable quantity of hydrogen can be added to the hydrotreatingprocess. The quantity of hydrogen used to contact the hydrocarboncontaining feed stock will generally be in the range of about 100 toabout 10,000 standard cubic feed H₂ per barrel of the hydrocarboncontaining feed stream and will more preferably be in the range of about1000 to about 6000 standard cubic feed H₂ per barrel of the hydrocarboncontaining feed stream.

In general, the catalyst composition is utilized primarily fordemetallization until a satisfactory level of metals (Ni, V) removal isno longer achieved. Catalyst deactivation generally results from thecoating of the catalyst composition with coke and metals removed fromthe feed. It is possible to remove the metals from the catalyst. But itis generally contemplated that once the removal of metals falls below adesired level, the spent (deactivated) catalyst will simply be replacedby fresh catalyst.

The time in which the catalyst composition of this invention willmaintain its activity for removal of metals and sulfur will depend uponthe metals concentration in the hydrocarbon containing feed streamsbeing treated. Generally the catalyst composition can be used for aperiod of time long enough to accumulate about 20-200 weight-% ofmetals, mostly Ni and V, based on the initial weight of the catalystcomposition, from the hydrocarbon containing feed. In other words, theweight of the spent catalyst composition will be about 20-200% higherthan the weight of the fresh catalyst composition.

Generally, at least a portion of the hydrotreated product stream havingreduced metal and sulfur contents is subsequently cracked in a crackingreactor, e.g. in a fluidized catalytic cracking unit, under suchconditions as to produce lower boiling hydrocarbon materials (i.e.,having a lower boiling range at 1 atm. than the feed hydrocarbons)suitable for use as gasoline, diesel fuel, lubricating oils and otheruseful products. It is within the scope of this invention to hydrotreatsaid product stream having reduced metal and sulfur contents in one ormore processes using different catalyst compositions, such asalumina-supported NiO/MoO₃ or CoO/MoO₃ catalysts, for further removal ofsulfur and other impurities, before the product stream is introducedinto the cracking reactor.

A further embodiment of this invention is a hydrofining processcomprising the step of introducing at least one thermally decomposablemetal compound into the hydrocarbon containing feed stream prior to itsbeing contacted with the catalyst composition of this invention. Themetal in the decomposable metal compound is selected from the groupconsisting of the metals of Group IV-B, Group V-B, Group VI-B, GroupVII-B, Group VIII and Group IB of the Periodic Table of Elements.Preferred metals are molybdenum, tungsten, manganese, chromium,zirconium and copper. Molybdenum is a particularly preferred metal whichmay be introduced as a carbonyl, acetylacetonate, carboxylate having1-12 C atoms per molecule (e.g., acetate, octoate, oxalate),naphthenate, mercaptide, dithiophosphate or dithiocarbamate. Molybdenumhexacarbonyl, molybdenum dithiophosphate and molybdenum dithiocarbamateare particularly preferred additives. The life of the catalystcomposition and the efficiency of the demetallization process isimproved by introducing at least one of the above-cited decomposablemetal compounds into the hydrocarbon-containing feed, which alsocontains metal such as nickel and vanadium. These additives can be addedcontinuously or intermittently and are preferably added at a time whenthe catalyst composition of this invention has been partiallydeactivated so as to extend its life.

Any suitable concentration of these additives may be added to thehydrocarbon-containing feed stream. In general, a sufficient quantity ofthe additive will be added to the hydrocarbon-containing feed stream toresult in a concentration of the metal (preferably molybdenum) in saiddecomposable compounds ranging from about 1 to about 1000 parts permillion and more preferably in the range of about 5 to about 100 partsper million in the feed stream.

Impregnated, Substantially Spherical Alumina-Containing Particles

Any suitable substantially spherical alumina-containing particles whichhave the following initial parameters can be used as said startingmaterial for step (a): average particle diameter of at least about 0.5inch, preferably in the range of from about 0.5 to about 1.5 inch, morepreferably from about 0.1 to about 1.0 inch; surface area (determined bythe BET/N₂ method; ASTM D3037) of at least about 20 m² /g, preferably inthe range of from about 40 to about 600 m² /g, more preferably in therange of from 100 to about 400 m² /g; a pore volume, as determined bymercury intrusion porosimetry (carried out at room temperature and amercury pressure varying from 0 psi to about 60,000 psi, using anAutopore 9200 instrument of Micromeritics, Norcross, GA), of at leastabout 0.1 cc/g, preferably in the range of from about 0.2 to about 1.0cc/g., more preferably from about 0.3 to about 0.7 cc/g; and content ofalumina, which generally is a mixture of gamma-alumina and amorphousalumina, of at least about 80 weight-% Al₂ O₃, preferably in the rangeof from about 90 to about 99 weight-% Al₂ O₃, more preferably from about93 to about 98 weight-% Al₂ O₃. The preferred starting material has anormalized crush strength per particle, determined as side plate crushstrength by means of a mechanical force gauge, such as the one describedin Example I, of at least 100 lb. per inch diameter per particle, morepreferably in the range of from about 100 to about 400 lb. per inchdiameter per particle; and a Na content of less than about 3.0 weight-%,more preferably below about 2.0 weight-% Na, most preferably below about0.5 weight-% Na. A presently particularly preferred starting material isa commercially available spherical, alumina-containing Claus catalystmaterial that is marketed by the Alumina Company of America, Pittsburgh,PA under the product designation of S-100 (see Example VI).

Preparation step (a) as described above, can be carried out in anysuitable manner. The solvent in the impregnating solution used in step(a) generally comprises water, and preferably consists essentially ofwater. Suitable solvents which can be used besides water are alcoholssuch as methanol, ethanol, ethylene glycol and the like, acetone, esterssuch as ethyl acetate, and the like. However, these non-aqueous solventsare presently not preferred. The concentration of ammonium thiosulfatein the impregnating solution of step (a) can be in the range of fromabout 0.05 to about 5 mol/l, preferably in the range of from about 0.1to about 1.0 mol/l (i.e., mols (NH₄)₂ S₂ O₃ per liter solution).

The impregnation of the alumina-containing starting material with theimpregnating solution can be carried out in any suitable manner.Preferably the starting material is soaked with the (NH₄)₂ S₂ O₃-containing impregnating solution, more preferably with agitation suchas mechanical stirring, for a period of time long enough (preferablyabout 0.2-2 hour) to allow dissolved ammonium thiosulfate to penetrateinto the substantially spherical, alumina-containing particles of thestarting material, more preferably to the core of these particles. Anysuitable weight ratio of said starting material to the impregnatingsolution can be employed. Preferably, the weight ratio of said startingmaterial to said impregnating solution will be in the range of fromabout 0.1:1 to about 2.0:1, more preferably from about 0.3:1 to about1.2:1. Even though presently not preferred, other impregnating methodscan be applied, such as spraying of the (NH₄)₂ S₂ O₃ -containingimpregnating solution onto the substantially spherical,alumina-containing particles of the starting material.

Even though the material obtained in step (a) can be directly processedin step (b), it is presently preferred to substantially dry theimpregnated material obtained in step (a) in drying step (a1). Thedrying step (a1) is generally carried out in air or an inert gas, at atemperature ranging from about 25° C. to about 200° C. (preferably50°-100° C.) so as to remove the greatest portion of water from themixture obtained in step (b). Vacuum conditions may be employed but arepresently not preferred. The at least partially dried mixture generallycontains less than about 20 weight-% water. The rate of drying iscontrolled so as to avoid surges of water vapor that can cause theimpregnating solution to splatter and can cause the particles to crack.Depending on the drying temperature and specific drying conditions (suchas extent of air movement; thickness of the solid layer to be dried),the drying time ranges generally from about 0.5 hour to about 100 hours,preferably from about 1 hour to about 30 hours.

The impregnated alumina-containing material obtained in step (a), oralternatively step (a1), is heated (calcined) at a temperature in therange of from about 500 to about 900° C., preferably from about 550 toabout 800° C., more preferably from about 600 to about 750° C. Theheating time is at least 10 minutes, preferably in the range of fromabout 10 minutes to 20 hours, more preferably from about 0.5 to about 10hours. The pressure can be atmospheric (preferred) or subatmospheric orsuperatmospheric. The heating process can be carried out in a freeoxygen containing gas atmosphere, such as air, or in an inert or in areducing gas atmosphere. Presently, heating in an O₂ -containing gas ispreferred. The gas atmosphere may contain water vapor, but the amount ofwater vapor should be minimized to less than about 10 volume percent.

Generally the above-described heating (calcining) of the impregnatedspherical, alumina-containing material results in a tolerable decreasein surface area, in a slight increase in total pore volume, but in asubstantial increase of the pore volume in pores having a pore diameterin the 40-200 Angstroms (A) range. Preferably, the impregnated,substantially spherical alumina-containing particles obtained by thepreparation process of this invention have a pore volume of pores in the40-200 A pore diameter range in excess of about 50%, more preferablyfrom about 50 to about 90% of the total pore volume. Preferably, thetotal BET/N₂ surface area of the impregnated, substantially sphericalparticles of this invention is in the range of from about 50 to about300 m² /g, and the total pore volume (determined by mercury porosimetry,discussed above) is in the range of from about 0.3 to about 0.8 cc/g.

The crush strength of the impregnated, substantially sphericalalumina-containing particles of this invention is preferably measuredafter they have been used in a hydrotreating process in the presence ofwater and sulfur compounds, as has been described above and also inExample V, so as to determine the retention of initial crush strengthunder these severe hydrotreating conditions (about 2250 psi totalpressure, about 400 psi partial pressure of steam, about 700° F., about100 hours; with at least about 0.5 weight-% sulfur in thehydrocarbon-containing feed). It is believed that the combination ofhydrogen, steam and sulfur compounds (resulting in H₂ S generation undercatalytic hydrotreating conditions) is particularly detrimental to thecrush strength of these particles. The thus determined crush strengthgenerally exceeds 150 lb. per inch diameter per particle and preferablyis in the range of about 150 to about 350 lb./inch/particle.

The impregnated, substantially spherical alumina-containing particles ofthis invention can be promoted with at least one element or compound atleast one element (i.e., one or mixture of two or more) selected fromthe group consisting of Y, La, Ce, Ti, Zr, Hf, Cr, Mo, W, Mn, Re, Ni,Co, Cu, Zn, P (as phosphite and/or phosphate), preferably Mo, Ni and Co,more preferably Mo. The total promoter level generally is relatively lowand suitably ranges from about 0.01 to about 3.0 weight-% of said atleast one element (i.e., one element or mixture of two or moreelements), preferably from about 0.1 to about 2.0 weight-%, morepreferably from about 0.2 to about 1.0 weight-% of said at least oneelement (most preferably Mo).

Any suitable technique for promoting the particles of this invention canbe employed. Preferably the impregnating solution used in step (a)contains one or more of the above-described promoters besides dissolved(NH₄)₂ S₂ O₃. The thus obtained particles, which additionally contain atleast one promoter compound, then undergo step (b), optionally afterstep (a1), as described above. It is, of course, possible (yet presentlynot preferred) to carry out step (a) without having any transition metaland/or phosphorus promoter compound present in the impregnatingsolution, and to impregnate the calcined material obtained in step (b)with a solution containing at least one promoter compound, followed bydrying and calcining (preferably at about 500°-900° C.) of the thustwice-impregnated material (so as to at least partially convert the atleast one transition metal compound to oxides of said metal). Generallythe crush strength of the impregnated, substantially sphericalalumina-containing particles is not substantially affected by thepresence of one or more promoters.

Fixed Catalyst Bed

In accordance with this invention, a fixed catalyst bed, suitable forhydrotreating substantially liquid hydrocarbon-containing feed streams,which also contain sulfur and metal compounds (as has been describedearlier for another embodiment of this invention), is providedcomprising at least one layer (X) of the impregnated, substantiallyspherical alumina-containing material of this invention, prepared by theprocess comprising steps (a), (b), and optionally, (a1).

In a preferred embodiment of this invention, the fixed catalyst bedcomprises at least one layer (X), as described above, and also at leastone layer (Y) of catalyst particles, different from those in layer (X).The catalyst particles in layer (Y) generally comprise an inorganicrefractory carrier. Non-limiting examples of such inorganic refractorycarrier materials are those that comprise (preferably consistessentially of) alumina (preferred), aluminum phosphate, silica,titania, zirconia, zirconium phosphate, ceria, boria, magnesia,silica-alumina, titania-silica, titania-alumina. In addition to thecarriers, the catalyst particles in catalyst bed layer (Y) comprise atleast one promoter selected from compounds of metals of Groups IIIB,IVB, VB, VIB, VIIB, VIII, IB and IIB of the Periodic Table. Presentlypreferred promoters are compounds of metals selected from the groupconsisting of Y, La, Ce, Ti, Zr, Cr, Mo, W, Mn, Re, Ni, Co and Cu, morepreferably oxides and/or sulfides of these metals, most preferably Mo,Ni, Co, and mixtures of any of these metal oxides and sulfides.Phosphorus compounds of these metals can also be present. Generally thetotal level of promoter ranges from about 0.5 to about 30 weight-%,preferably from about 1 to about 15 weight-%, based on the elementalmetal. Generally the BET/N₂ surface area of the particles in layer (Y)is in the range of from about 50 to about 500 m² /g, and their porevolume (measured by mercury porosimetry) is in the range of from about0.2 to about 2.0 cc/g.

The catalyst particles in layer (Y) can be prepared by any suitabletechnique such as by impregnation of the carrier (preferably alumina)with one or more solutions containing one or more compounds of thepromoter metals (plus, optionally, one or more compounds of phosphorus)and subsequent drying and calcining (this method presently beingpreferred) as has been described for promoted particles in layer (X); orby coprecipitation e.g., of hydrogels of alumina and promoter metal(e.g., Ni, Co, Mo), followed by drying and calcining. Suitablecommerically available catalyst materials for layer (Y) are described inExample V.

Layers (X) and (Y) can be arranged in the fixed catalyst bed of thisinvention in any suitable manner. In one preferred embodiment, layer (X)is placed as support layer below at least one catalyst layer (Y). Inanother embodiment, layer (X) is placed as a cover layer on top of atleast catalyst layer (Y). In a further embodiment, catalyst layer (Y) isplaced between at least two layers (X). In a still further embodiment,in which at least three layers (X) and at least two catalyst layers (Y)(which are different from each other) are employed, one layer (X) isplaced on top of said at least two catalyst layers (Y), one layer (X) isplaced as interlayer between two different catalyst layers (Y), and athird layer (X) is placed below said at least two lower catalyst layer(Y). Another suitable catalyst bed arrangement is shown in FIG. I. Theweight ratio of each catalyst layer (X) to each catalyst layer (Y) isgenerally in the range of from about 1:100 to about 1:1, preferably fromabout 1:20 to about 1:5.

The dimensions of catalyst bed layer (X) comprising the substantiallyspherical alumina-containing particles obtained by the above-describedheating process are not considered critical and depend on the dimensionof the hydrotreating reactor that holds the fixed catalyst bed.Generally the height of each layer (X) ranges from about 1 to about 50feet in commercial hydrotreating operations. It is within the scope ofthis invention to have additionally inert particles present (up to 50weight-%) in layer (X), such as shaped inert ceramic particles. Theheight of each catalyst layer (Y) can vary widely, depending on theparticular reactor dimensions.

If desired, the fixed catalyst bed of this invention can be sulfided bytreatment with a fluid stream that contains sulfur compounds, generallyprior to said hydrotreating process. Non-limiting examples of such fluidstreams are solutions of mercaptans, of mercaptoalcohols, of organicsulfides or of organic disulfides in a suitable organic solvent (such asgas oil and other petroleum fractions), and gas streams that comprise H₂S, such as mixtures of H₂ and H₂ S. This sulfiding procedure isgenerally carried out at an elevated temperature (preferably at about400°-700° F.) for a period of time sufficient (preferably from about0.5-20 hours) so as to convert at least a portion of compounds of one ormore metals contained in particles of layer (Y), and optionally also inparticles of layer (X), to sulfides of said one or more metals.

In general, the fixed catalyst bed of this invention is utilizedprimarily for demetallization and desulfurization. The time in which thefixed catalyst bed of this invention will maintain its activity for theabove process will depend upon the hydrotreating conditions and thecomposition of the hydrocarbon-containing feed. Generally, thetemperature of the hydrotreating process is gradually increased tocompensate for loss of catalyst activity due to fouling (e.g., due todeposition of coke and metals as the catalyst). The entire fixedcatalyst bed or one or more layers of the fixed catalyst bed can, ifdesired, be regenerated when the catalytic activity has dropped below adesired level. Catalyst regeneration can be carried in-situ bydiscontinuing the flow of hydrogen and of the hydrocarbon-containingfeed streams, purging the fixed bed reactor with an inert gas (e.g., N₂)and then heating the fixed catalyst bed in a free oxygen-containing gasatmosphere (such as air), under such conditions as to removecarbonaceous materials and to at least partially convert sulfides oftransition metals such as Mo, Co and/or Ni back to their oxides and/orphosphates. Preferably, however, the fixed bed layers are removed fromthe cooled hydrotreating reactor after said purging and are transferredto another reactor where the catalyst regeneration takes place.Generally the catalyst regeneration step is carried out at about400°-600° C. and at a pressure of about 0-1,000 psig.

The following examples are presented in further illustration of theinvention and are not to be considered as unduly limiting the scope ofthis invention.

Example I

This example illustrates the preparation of various promotedalumina-containing materials, useful as catalyst for hydrogenation andhydrotreating processes.

Catalyst 1 (Control) was prepared by mixing 20 grams of sphericalalumina (diameter 1-2 mm, BET/N₂ surface area: 130 m² /g; pore volume,as determined by mercury intrusion porosimetry: 1.0 cc/g; supplied byAlcoa Chemicals Division of Aluminum Company of America, Pittsburg, PA)with about 22 g of an aqueous impregnating solution containing 2.94 gcitric acid, 2.94 g (NH₄)₆ Mo₇ O₂₄ ·4H₂ O, Ni(NO₃)₂ ·6H₂ O and 0.79 gCo(NO₃)·6H₂ O. The mixture of alumin impregnating solution was air-driedand then calcined at 800° F. for 3 hours. Catalyst 1 contained 0.7weight-% Ni, 0.7 weight-% Co and 7.0 weight-% Mo.

Catalyst 2 (Control) was prepared by first soaking 26.5 g of sphericalalumina (see above) with a pretreating solution containing 5 g NH₄ HSO₄in 100 cc deionized water, for about 3 minutes at room temperature.Excess pretreating solution was decanted. The thus pretreated aluminawas dried, soaked with about 29 g of an impregnating solution containing3.7 g citric acid, 3.7 g (NH₄)₂ Mo₇ O₂₄ ·4H₂ Ni(NO₃)₂ ·6H₂ O and 1.0 gCo(NO₃)₂ ·6H₂ O, air-drie for 3 hours. Catalyst 2 contained 0.7 weight-%Ni, 0.7 weight-% Co and 7.0 weight-% Mo.

Catalyst 3 (Control) was prepared essentially in accordance with themethod for making Catalyst 2, except that the pretreating solutioncontained 5 g (NH₄)₂ SO₄ (in lieu of NH₄ HSO₄) in 100 cc H₂ O. Catalyst3 contained 0.7 weight-% Ni, 0.7 weight-% Co and 7.0 weight-% Mo.

Catalyst 4 (Invention) was prepared essentially in accordance with themethod for making Catalyst 2, except that the pretreating solutioncontained 5 g (NH₄)₂ S₂ O₃ (in lieu of NH₄ HSO₄) in 100 cc H₂ O.Catalyst 4 containing 0.7 weight-% Ni, 0.7 weight-% Co and 7.0 weight-%Mo.

Example II

This example illustrates the use of the catalyst compositions describedin Example I in test runs for hydrogenating olefinic hydrocarbons.

A stainless steel reactor having a length of about 29 inches and aninner diameter of about 0.75 inch was filled with a top layer of 25 ccof low surface area α-alumina (14 mesh alundum; surface area less than 1m² /g), a middle layer of a mixture of 25 cc of alundum and 5 cc of oneof the catalyst compositions described in Example I, and a bottom layerof 28 cc of alundum. Cyclohexene feed was introduced from the top intothe reactor at a rate of 8-9 cc/hr, and hydrogen gas was introduced fromthe top at a rate of 200 cc/min. The total pressure was about 150 psigat reaction conditions. The temperature of the reactor was then slowlyincreased to the desired reaction temperature of about 150°-250° C.Samples of the product were taken at various time intervals (generallyevery hour) and analyzed for cyclohexene and cyclohexane content bymeans of a gas chromatograph. Average conversion results of last runs atthree reaction temperatures generally lasting about 25 hours aresummarized in Table I. Essentially the entire formed product wascyclohexane.

                  TABLE I                                                         ______________________________________                                                 % Conversion of Cyclohexene                                          Catalyst   at 150° C.                                                                         at 200° C.                                                                       at 250° C.                            ______________________________________                                        1 (Control)                                                                              81          80        98                                           2 (Control)                                                                              69          68        91                                           3 (Control)                                                                              46          78        97                                           4 (Invention)                                                                            97          94        99                                           ______________________________________                                    

Date in Table I clearly show that, unexpectedly, Invention Catalyst 4,wherein the alumina support had been pretreated with ammoniumthiosulfate, (NH₄)₂ S₂ O₃, was a considerably more active olefinhydrogenation catalyst than Control Catalyst 1 (no pretreatment ofalumina support), Control Catalyst 2 (the alumina support of which hadbeen pretreated with NH₄ HSO₄) and Control Catalyst 3 (the aluminasupport of which had been pretreated with (NH₄)₂ SO₄).

Example III

In this example, the automated experimental setup for investigating thehydrofining of heavy oils in accordance with the present invention isdescribed. Oil was pumped downward through an induction tube into atrickle bed reactor. 28.5 inches long and 0.75 inches in diameter. Theoil pump used was a reciprocating pump with a diaphragm-sealed head. Theoil induction tube extended into a catalyst bed (located about 3.5inches below the reactor top) comprising a top layer of about 25 cc oflow surface area α-alumina (14 mesh alundum; surface area less than 1 m²/gram), a middle layer of 13 cc (6.9 g) of one of the hydrofiningcatalysts described in Example I mixed with 57 cc of 36 mesh alundum,and a bottom layer of about 15 cc of alundum.

The heavy oil feed was a mixture of 50 volume-% 400 F+ Hondo residiumand 50 volume-% light cycle oil. The feed contained about 3.1 weight-%sulfur, 54 ppmw (parts per million by weight) nickel and 124 ppmwvanadium.

Hydrogen was introduced into the reactor through a tube thatconcentrically surrounded the oil induction tube but extended only tothe reactor top. The reactor was heated with a 3-zone furnace. Thereactor temperature was measured in the catalyst bed at three differentlocations by three separate thermocouples embedded in axial thermocouplewell (0.25 inch outer diameter). The liquid product oil was collectedevery day for analysis. The hydrogen gas was vented. Vanadium and nickelcontents were determined by plasma emission analysis and the sulfurcontent was measured by X-ray fluorescence spectrometry.

Example IV

This example illustrates the removal of metals (Ni, V) and sulfur fromthe heavy oil feed (see Example III) by hydrotreatment in the presenceof Catalysts 1-4. Pertinent process conditions were: LHSV of about 1.0cc oil/cc catalyst/hr; hydrogen flow rate of about 2500 per cubic feetH₂ per barrel oil; reaction pressure of about 2250 psig; and reactiontemperature of about 700° F. Catalysts 1-4 had been presulfided (beforethe hydrotreating tests) by heating in a mixture of H₂ and H₂ S (H₂ /H₂S volume ratio was 10:1.4) at about 400°-700° F. for about 8 hours.Pertinent hydrotreating test results are summarized in Table II.

                  TABLE II                                                        ______________________________________                                               Days on         Product Analysis                                       Catalyst Stream            Wt % S ppmw (Ni + V)                               ______________________________________                                        1        1                 1.28   59.3                                        (Control)                                                                              2                 1.55   71.7                                                 3                 1.66   74.4                                                 4                 1.93   88.5                                                          Average  1.6    74                                          2        1                 1.51   74.4                                        (Control)                                                                              2                 1.63   71.1                                                 3                 1.70   84.4                                                 4                 1.65   67.0                                                          Average  1.6    74                                          3        1                 1.54   80.7                                        (Control)                                                                              2                 1.81   88.1                                                 3                 1.78   77.2                                                 4                 1.91   84.2                                                          Average  1.8    83                                          4        1                 1.21   61.9                                        (Invention)                                                                            2                 1.15   52.3                                                 3                 1.36   57.8                                                 4                 1.47   61.5                                                          Average  1.3    58                                          ______________________________________                                    

Data in Table II clearly show that, unexpectedly, Invention Catalyst 4(wherein alumina support had been pretreated with (NH₄)₂ S₂ O₃) was moreeffective in removing sulfur and metals from the oil feed than ControlCatalyst 1 (no pretreatment of alumina support) and Control Catalysts 2and 3 (wherein alumina had been pretreated with NH₄ HSO₄ and (NH₄)₂ SO₄,respectively).

Example V

This example illustrates the evaluation of catalyst bed supportparticles in oil hydrotreating tests, in the presence of steam. Thepurpose of this evaluation procedure is to determine thehydrodemetallization activity and the retention of crush strength ofthese support particles under severe hydrotreating conditions, in thepresence of steam and sulfur compounds.

The catalyst bed arrangement (simulating proportions of a typicalrefinery bed loading) which was used in the evaluation tests is shown inFIG. 1. The catalyst bed column had a diameter of about 0.75 inches.Particles A were substantially spherical alumina-containing particles,which can be any of the particles A1 through A12 described in moredetail in Example II. Material B was a commercial alumina-supportedhydrotreating catalyst comprising 0.9 weight-% Co, 0.5 weight-% Ni and7.5 weight-% Mo, havig a BET/N₂ surface area of 174 m² /g and a porevolume of 0.63 cc/g (measured by mercury intrusion porosimetry).Material C was a commercial alumina-based hydrotreating catalystcomprising 3.1 weight-% Ni, 7.9 weight-% Mo and 4.6 weight-% Ti having aBET/N surface area of 140 m² /g and a pore volume (by Hg intrusionporosimetry) of 0.5 cc/g. Material D was a commercial alumina-basedhydrotreating catalyst comprising 2.4 weight-% Co and 6.7 weight-% Mo,having a BET/N₂ surface area of 290 m² /g and pore volume (by Hgintrusion porosimetry) of 0.47 cc/g.

A heavy-oil water mixture containing about 4-8 volume-% H₂ O was pumpedto a metallic mixing T-pipe where it was mixed with a controlled amountof hydrogen gas. The heavy oil was a Maya 400F+ resid having an API⁶⁰gravity of 14.0, containing 3.8 weight-% sulfur and about 350 ppmw(Ni+V) (parts by weight of Ni+V per million parts by weight of oilfeed). The oil/water/hydrogen mixture was pumped downward through astainless steel trickle bed reactor which contained the multi-layercatalyst bed described above (see FIG. 1). The tubular reactor was about28.5 inches long, had an inner diameter of about 0.75 inches, and wasfitted inside with a 0.25 inch O.D. axial thermocouple well. The reactorwas heated by a 3-zone furnace. The reactor temperature was usuallymeasured in four locations along the reactor bed by a travelingthermocouple that was moved within the axial thermocouple well.

Generally, the hydrotreating conditions were as follows: reactiontemperature of about 690°-720° F.; liquid hourly space velocity (LHSV)of about 0.3 cc/cc catalyst/hour; about 2,250 psig total pressure; about400 psig H₂ O (steam) partial pressure; time on stream: about 100-200hours. When it was desired to determine the desulfurization anddemetallization activity of the catalyst bed, the liquid product wasfiltered through a glass filter and analyzed for sulfur, nickel andvanadium by plasma emission analysis.

After completion of a hydrotreating test, the reactor with catalyst bedwas flushed with xylene so as to remove undrained oil. Thereafter,nitrogen gas was passed through the xylene-washed catalyst bed so as todry it. The various catalyst layers were carefully removed. Particles A,B or C were tested for crush strength in a Mechanic Force Gauge D-75M ofHunter Spring, Division of Ametek, Hot Field, PA. A single sphere of Aor B or C, the average diameter of which had been measured, was placedbetween the metal plates of D-75M, and the plates were slowly movedtoward one another by means of an electric motor. The force applied tothe plates was displayed by a gauge. The force necessary to fracture(crush) a catalyst sphere was recorded as the crush strength of thesphere. The normalized crush strength, defined as crush strength of asphere divided by its average particle diameter (lb/sphere/inchdiameter), was calculated.

Example VI

This example illustrates the preparation of the substantially sphericalalumina-containing particles of this invention and of otheralumina-containing catalyst bed particles.

Control Particles Al were spherical, Co/Mo-promoted alumina particles,marketed by Shell Chemical Company, Houston, TX under the productdesignation "Shell 544", suitable as support balls for hydrotreatingcatalyst beds. Pertinent properties of Particles Al were: diameter of1/6 inch; cobalt content of 1.7 weight-%; molybdenum content of 5.3weight-%; surface area of 300+ m² /g; total pore volume of 0.47 cc/g;loss on ignition (LOI; weight loss when heated to 482° C.) of 0.8weight-%; compacted bulk density (compacted loading density) of about0.83 g/cc; and side plate crush strength of 30+ lb/particle (i.e., about190 lb/particle/inch diameter).

Control Particles A2 were substantially spherical, substantiallyunpromoted alumina-containing particles having an average particlediameter of 1/4 inch; a BET/N₂ surface area of about 325 m² /g; a totalpore volume of about 0.50 m² /g; and average normalized individual ballcrush strength of about 240 lb/particle/inch diameter (i.e., the actualcrush strength of a 1/4" sphere was about 60 lb/particle); Al₂ O₃content of about 94.6 weight-%; Na₂ O content of about 0.35 weight-%;and LOI content (weight loss when heated from 250° C. to 1200° C.; ameasure of hydroxyl content) of 5.0 weight-%. Particles A2 were suppliedby Aluminum Company of America, Pittsburgh, PA under the productdesignation of S-100.

Control Particles A3 were obtained when Control Particles A2 were heatedat about 650° C. for about one hour.

Control Particles A4 were obtained by soaking 100 grams of ControlParticles A2 with an aqueous solution containing about 1.1 grams ofammonium heptamolybdate, (NH₄)₆ Mo₇ O₂₄ ·H₂ O (provided by AlfaProducts, Danvers, MA), dissolved in 100 cc of deionized water for about20 minutes, as to provide a promoter level of about 0.3 weight-% Mo inthe particles (after calcining); decanting excess solution; drying thethus impregnated particles at about 150° C. for about 2 hours, and thencalcining them at about 650° C. for about 2 hours in air.

Control Particles A5 also contained about 0.3 weight-% Mo, and wereobtained when 60 grams of Control Particles A2 were soaked in 100 cc ofan aqueous solution containing about 1.1 grams of ammoniumheptamolybdate and about 3.0 grams of ammonium bisulfate, NH₄ HSO₄, forabout 30 minutes, decanting excess solution, drying at about 150° C. forabout 2 hours and calcining at about 650° C. for about 2 hours in air.

Control Particles A6 were prepared essentially in accordance with thepreparation of Particles A5, except that (NH₄)₂ SO₄ (3.0 grams) was usedin lieu of NH₄ HSO₄.

Invention Particles A7 were prepared essentially in accordance with thepreparation procedure for Particles A5, escept that (NH₄)₂ S₂ O₃ (3.0grams) was used in lieu of NH₄ HSO₄.

Invention Particles A8, A9, A10, A11 and A12 were prepared by soakingControl Particles A2 with an aqueous solution containing about 0.5 g,1.0 g, 2.0 g, 4.0 g and 10.0 g, respectively, of (NH₄)₂ S₂ O₃ cc H₂ O(no Mo compound present) for about 30 minutes; decanting excesssolution; drying the thus treated particles and calcining them at about650° C. for about 2 hours in air. Particles A10 contained about 0.5weight-% sulfur, Particles A11 contained about 0.7 weight-% sulfur andParticles A12 contained about 1.4 weight-% sulfur (determined aftercalcining).

Example VII

This example illustrates the effect of the impregnation of sphericalalumina particles with various ammonium salts on the crush strength ofthe calcined particles.

In one test series, the average crush strength of Invention Particles A7was compared with the average crush strength of Control Particles A4, A5and A6, measured in accordance with the procedure described in ExampleV. Test results are summarized in Table III.

                  TABLE III                                                       ______________________________________                                                              Wt % of                                                          NH.sub.4 Salts in                                                                          NH.sub.4 Salt                                                                            Crush Strength                               Particles                                                                              Impregn. Solution                                                                          in Solution                                                                              (Lb/Particle)                                ______________________________________                                        A4       None         0          8.2                                          (Control)                                                                     A5       NH.sub.4 HSO.sub.4                                                                         3.0        8.3                                          (Control)                                                                     A6       (NH.sub.4).sub.2 SO.sub.4                                                                  3.0        9.0                                          (Control)                                                                     A7       (NH.sub.4).sub.2 S.sub.2 O.sub.3                                                           3.0        12.9                                         (Invention)                                                                   ______________________________________                                    

Test data in Table III clearly demonstrate the significant improvementin crush strength (after hydrotreating in the presence of steam) ofInvention Particles A7 (pretreated with (NH₄)₂ S₂ O₃) versus ControlParticles A5 and A6 (pretreated with NH₄ HSO₄ and (NH₄)₂ SO₄respectively). Particles A4-7 all contained about 0.3 weight-% Mo.

In another test series, the effect of the concentration of (NH₄)₂ S₂ O₃in the impregnating solution on the crush strength, determined inaccordance with the procedure of Example V, of calcined Particles A8through A12 was investigated. Test results are shown in FIG. 2. Thecrush strength of Particles A12 (treated with a 10 wt-% (NH₄)₂ S₂ O₃solution) was about twice that of untreated Particles A2. Sinceanalytical test results indicated that the calcined, (NH₄)₂ S₂ O₃-impregnated invention particles contained sulfur (see Example VI), itis believed that the incorporation of sulfate ions into the aluminastructure of the spherical particles was responsible for the enhancedhydrothermal crush strength retention.

Example VIII

This example illustrates the effect of the heating (calcining)conditions on pertinent physical properties of alumina-containingspheres. A2 particles of about 1/8 inch diameter that had beenimpregnated with about 0.3 weight-% Mo were heated in air attemperatures ranging from 400° C. to 900° C. for about 1 hour (so as toprepare Particles A4). The crush strength of the thus calcined particles(diameter: 1/8 inch) was determined in accordance with the proceduredescribed in Example V. Test results are summarized in Table IV and areplotted in FIG. 3.

                  TABLE IV                                                        ______________________________________                                                    Crush      Normalized                                             Calcination Strength   Crush Strength                                         Temp. (°C.)                                                                        (lb/Particle)                                                                            (lb/Inch Diameter)                                     ______________________________________                                        400         1.88       15.0                                                   500         3.42       27.4                                                   600         4.37       35.0                                                   700         4.80       38.4                                                   800         3.95       31.6                                                   900         1.65       13.2                                                   ______________________________________                                    

Data in Table IV and FIG. 3 clearly show that maximum crush strength(after hydrotreating in the presence of steam) was attained when thealumina spheres (containing 0.3 weight-% Mo) were calcined at atemperature in the range of from about 550 to about 800° C., preferablyfrom about 600 to about 750° C.

The effect of the calcination time, at a calcination temperature of 650°C., is shown in Table V.

                  TABLE V                                                         ______________________________________                                        Calcination  Crush Strength                                                                            Crush Strength                                       Time (minutes)                                                                             (lb/Particle)                                                                             (lb/Inch Diameter)                                   ______________________________________                                        20           7.01        56.1                                                 40           7.25        58.0                                                 60           7.20        57.6                                                 90           6.68        53.4                                                 120          6.41        51.3                                                 240          5.22        41.8                                                 ______________________________________                                    

Data in Table V show that a calcination time of about 20-90 minutes wassuitable for 1/8 inch diameter alumina-containing Particles A4.Prolonged calcining had a detrimental effect.

Based on the above-described test results, it is concluded that thepreferred heating conditions in step (A) for preparing the (NH₄)₂ S₂ O₃-impregnated, substantially spherical alumina-containing particles ofthis invention (such as Particles A1 through A12) will also comprise atemperature of about 550°-800° C. (more preferably about 600°-750° C.)and a heating time of about 20-90 minutes.

Example IX

The effect of the calcination temperature of the pore volumedistribution of Particles A1, A2 and A3 was investigated. Pore volumeand pore diameter of these particles were determined by measuringintrusion porosimetry (carried out at room temperature at a mercuryranging from 0 psi to 60,000 psi, using an Autopore 9200 instrument ofMicromeritics, Norcross, GA). In FIG. 4, pore volume was plotted versuslogarithm of pore diamter for A1, A2 and two A3 samples. FIG. 4 showsthat Al (Shell 544, as received; 1/6" diameter) and of A2 (Alcoa S-100,as received; 1/16" diameter) had very similar pore distributions,whereas the pore distributions of the two A3 samples (obtained byheating 1/16" A2 particles at 600° C. and 800° C., respectively, forabout 3 hours), differed significantly from those of A1 and A2. The mostsignificant changes that resulted when A2 (S-100) particles were heatedto 600° C. and 800° C., respectively, (so as to make A3 particles), wasa shift toward a substantially greater portion of pores in the 40-200Apore diameter range. About 80% of the total pore volume of A3 was inpores of the 40-200 Angstrom range, whereas the percentage of the totalpore volume of A1 and A2 in the 40-200 Angstrom pore diameter range wasonly about 40%.

Based on the above-described test results, it is concluded that heatingat 600°-800° C. in step (A) for preparing the (NH₄)₂ S₂ O₃ -impregnated,substantially spherical alumina-containing particles of this inventionwill have a very similar effect in the pore volume distribution of theparticles of this invention (such as Particles A7 through A12) as theabove-described effect on the pore volume distribution of Particles A3.

The total pore volume of the Mo-impregnated alumina spheres A3 rangedfrom about 0.5 to about 0.6 cc/g when the calcination was carried outfor 16 hours at a temperature in the range of from about 400° C. toabout 800° C. Thus, the effect of the calcination temperature on thetotal pore volume of calcined spheres A3 was rather insignificant. Basedon these results, it is concluded that the total pore volume of the(NH₄)₂ S₂ O₃ -impregnated, substantially spherical alumina-containingparticles of this invention (such as Particles A7 through A12) will alsovary only insignificantly with the calcination temperature.

Example X

This example illustrates the improved performance of Particles A4 (with0.3 weight-% Mo) in prolonged hydrotreating tests versus Particles A1and A2. Crush strength results, obtained substantially in accordancewith the hydrotreating procedure described in Example I, are summarizedin Table III. Hydrotreating conditions were: 2200 psig total pressure;760° F.; 110 psi steam pressure, LHSV of 0.1 cc/cc catalyst/hour. Theresid feed contained about 2.0 weight-% sulfur and about 60 ppmw (Ni+V).

                  TABLE VI                                                        ______________________________________                                                  Hours on Stream:                                                              0     16      30     140  270  360                                  Particles.sup.1                                                                           Crush Strength (lb/Particle)                                      ______________________________________                                        1/6" A1     35      11      N/A  N/A  N/A  N/A                                1/4" A2     58      11      N/A  N/A  N/A  N/A                                1/4" A4     55      39      37   34   38   38                                 1/4" A4      100+    80+    80+  80+  80+  80+                                1/8" B      49      N/A     42   N/A  N/A  N/A                                ______________________________________                                         .sup.1 Fractions indicate particle diameter expressed in inches.         

Test data in Table VI clearly show a significant improvement in crushstrength retention of Particles A4 over commercial Particles A1 and A2,after use in the several hydrotreating runs in the presence of steam, asdescribed in Example V. Based on these results and based on the factthat the (NH₄)₂ S₂ O₃ -impregnated, substantially sphericalalumina-containing Particles A7 through A12 of this invention have ahigher crush strength retention than Particles A4 (see Table III andspecifically FIG. 2), it is concluded that the (NH₄)₂ S₂ O₃-impregnated, substantially spherical alumina-containing particles ofthis invention will also be superior to Particles A1 and A2, in terms ofcrush strength retention.

Reasonable variations and modifications are possible within the scope ofthe disclosure and appended claims.

That which is claimed is:
 1. A process for preparing a composition ofmatter comprising the steps of(A) impregnating a support materialcomprising alumina with a solution comprising water and at least onedissolved thiosulfate compound; (B) heating the material obtained instep (A) under such conditions as to at least partially dry saidmaterial obtained in step (A); (C) impregnating the at least partiallydried material obtained in step (B) with a solution comprising a liquidsolvent and at least one dissolved compound of at least one metalselected from the group consisting of transition metals belonging toGroup VB, Group VIB, Group VIIB, Group VIII and Group IB of the PeriodicTable of Elements; (D) heating the material obtained in step (C) at afirst temperature so as to at least partially dry said material obtainedin step (C); and (E) heating the at least partially dried materialobtained in step (D) at a second temperature, which is higher than saidfirst temperature, so as to activate said at least partially driedmaterial obtained in step (D).
 2. A process in accordancd with claim 1wherein said thiosulfate compound used in step (A) is (NH₄)₂ S₂ O₃.
 3. Aprocess in accordance with claim 2 wherein the concentration of (NH₄)₂S₂ O₃ in the solution used in step (A) is in the range of from about 1to about 200 grams per liter.
 4. A process in accordance with claim 3wherein the weight ratio of said support material to said solution usedin step (A) is in the range of from about 1:20 to about 5:1.
 5. Aprocess in accordance with claim 1 wherein said support material used instep (A) has a surface area, determined by ASTM method D3037, of about20 to about 350 m² /g, and a pore volume, measured by mercury intrusionporosimetry, of about 0.2 to about 2.0 cc/g.
 6. A process in accordancewith claim 5 wherein said support material consists essentially ofalumina.
 7. A process in accordance with claim 1 wherein heating steps(B) and (D) are carried out at a temperature of about 40 to about 300°C., and heating step (E) is carried out at a temperature of about 300°C. to about 700° C.
 8. A process in accordance with claim 1 wherein saidliquid solvent of the solution used in step (C) is water, theconcentration of said at least one dissolved compound of at least onemetal is in the range of from about 0.01 to about 5.0 mol/l, and theweight ratio of said at least partially dried material obtained in step(B) to said solution used in step (C) is in the range of from about1:100 to about 10:1.
 9. A process in accordance with claim 1 whereinsaid at least one metal in said at least one dissolved compound used instep (C) is selected from the group consisting of Mo, Ni and Co, and theweight percentage of said at least one metal in the activated materialobtained in step (E) is in the range of from about 0.1 to about 25weight-%.
 10. A process in accordance with claim 1 further comprisingthe step of(F) contacting the activated material obtained in step (D)with at least one suitable sulfur containing compound under suchconditions as to at least partially convert transition metal compoundscontained in said activated material to transition metal sulfides.
 11. Acomposition of matter prepared by the process comprising the steps of(A)impregnating a support material comprising alumina with a solutioncomprising water and at least one dissolved thiosulfate compound; (B)heating the material obtained in step (A) under such conditions as to atleast partially dry said material obtained in step (A); (C) impregnatingthe at least partially dried material obtained in step (B) with asolution comprising a liquid solvent and at least one dissolved compoundof at least one metal selected from the group consisting of transitionmetals belonging to Group VB, Group VIB, Group VIIB, Group VIII andGroup IB of the Periodic Table of Elements; (D) heating the materialobtained in step (C) at a first temperature so as to at least partiallydry said material obtained in step (C); and (E) heating the at leastpartially dried material obtained in step (D) at a second temperature,which is higher than said first temperature, so as to activate said atleast partially dried material obtained in step (D).
 12. A compositionof matter in accordance with claim 11 wherein said thiosulfate compoundused in step (A) is (NH₄)₂ S₂ O₃.
 13. A composition of matter inaccordance with claim 12 wherein the concentration of (NH₄)₂ S₂ O₃ inthe solution used in step (A) is in the range of from about 1 to about200 grams per liter.
 14. A composition of matter in accordance withclaim 13 wherein the weight ratio of said support material to saidsolution used in step (A) is in the range of from about 1:20 to about5:1.
 15. A composition of matter in accordance with claim 11 whereinsaid support material used in step (A) has a surface area, determined bythe ASTM method D3037, of about 20 to about 350 m² /g, and a porevolume, measured by mercury intrusion porosimetry, of about 0.2 to about2.0 cc/g.
 16. A composition of matter in accordance with claim 15wherein said support material consists essentially of alumina.
 17. Acomposition of matter in accordance with claim 11 wherein heating steps(B) and (D) are carried out at a temperature of about 40 to about 300°C., and heating step (E) is carried out at a temperature of about 300°C. to about 700° C.
 18. A composition of matter in accordance with claim11 wherein said liquid solvent of the solution used in step (C) iswater, the concentration of said at least one dissolved compound of atleast one metal is in the range of from about 0.01 to about 5.0 mol/l,and the weight ratio of said at least partially dried material obtainedin step (B) to said solution used in step (C) is in the range of fromabout 1:100 to about 10:1.
 19. A composition of matter in accordancewith claim 11 wherein said at least one metal in said at least onedissolved compound used in step (C) is selected from the groupconsisting of Mo, Ni and Co, and the weight percentage of said at leastone metal in the activated material obtained in step (E) is in the rangeof from about 0.1 to about 25 weight-%.
 20. A composition of matter inaccordance with claim 11 wherein said process further comprises the stepof(F) contacting the activated material obtained in step (D) with atleast one suitable sulfur containing compound under such conditions asto at least partially convert transition metal compounds contained insaid activated material to transition metal sulfides.
 21. A compositionof matter comprising impregnated, substantially sphericalalumina-containing particles, having been prepared by the processcomprising the steps of(a) impregnating (i) a starting material ofsubstantially spherical alumina-containing particles which have aninitial average particle diameter of at least about 0.05 inch, aninitial surface area, as determined by the BET method employingnitrogen, of at least 20 m² /g, an initial pore volume, as determined bymercury intrusion porosimetry, of at least about 0.1 cc/g, and aninitial content of Al₂ O₃ of at least about 80 weight-%, with (ii) asolution consisting essentially of water, at least one dissolvedcompound of at least one element selected from the group consisting ofmolybdenum, cobalt and nickel, and dissolved ammonium thiosulfate; and(b) heating the material obtained in step (a) at a temperature in therange of from about 500 to about 900° C. for a period of time of atleast 10 minutes, under such heating conditions as to obtain a materialhaving a higher crush strength than said starting material, wherein saidcrush strength is measured after exposure of each of said materials forabout 100 hours to a liquid hydrocarbon-containing stream which containsat least about 0.5 weight-% sulfur, under hydrotreating conditions atabout 2250 psig total pressure, about 400 psig partial pressure of steamand about 700° F.
 22. A composition of matter in accordance with claim21 wherein said starting material used in step (a) has an initialaverage particle size in the range of from about 0.1 to about 1.0 inch,an initial surface area in the range of from about 40 to about 600 m²/g, an initial pore volume in the range of from about 0.2 to about 1.0cc/g, and an initial normalized crush strength in the range of fromabout 100 to about 400 lb. per inch diameter per particle.
 23. Acomposition of matter in accordance with claim 21 wherein the initialcontent of Na in said starting material is below about 2.0 weight-%, andsaid initial content of Al₂ O₃ in said starting material is in the rangeof from about 90 to about 99 weight-%.
 24. A composition of matter inaccordance with claim 31 wherein the concentration of dissolved ammoniumthiosulfate in the impregnating solution used in step (a) is in therange of from about 0.05 to about 5 mol/l, and the weight ratio of saidstarting material to said impregnating solution is in the range of fromabout 0.1:1 to about 2.01:1.
 25. A composition of matter in accordancewith claim 24 wherein said concentration of dissolved ammoniumthiosulfate is in the range of from about 0.1 to about 1.0 mol/l.
 26. Acomposition of matter in accordance with claim 21 wherein said heatingin step (b) is carried out at a temperature in the range of from about550 to about 800° C. for a period of time in the range of from about 10minutes to about 20 hours.
 27. A composition of matter in accordancewith claim 21 wherein said impregnated, substantially sphericalalumina-containing particles obtained in step (b) have a pore volume ofpores possessing a diameter of about 40-200 Angstroms in the range offrom 50% to about 90% of the total pore volume, and a normalized crushstrength in the range of from about 150 to about 350 lb. per inchdiameter per particle.
 28. A composition of matter in accordance withclaim 21 wherein said impregnated, substantially sphericalalumina-containing particles obtained in step (b) have a surface area inthe range of from about 50 to about 300 m² /g and a pore volume in therange of from about 0.3 to about 0.8 cc/g.
 29. A composition inaccordance with claim 21 comprising said at least one element at a levelof from about 0.01 to about 3.0 weight-%.
 30. A composition of matter inaccordance with claim 29 wherein said at least one element is molybdenumand is present at a level of from about 0.1 to about 2.0 weight-% Mo.31. A composition of matter in accordance with claim 21 wherein saidimpregnated, substantially spherical alumina-containing particles arecontained in at least one layer (X) of a fixed hydrotreating catalystbed.
 32. A composition of matter in accordance with claim 31additionally comprising at least one layer (Y) of catalyst particlescomprising a refractory inorganic carrier and at least one hydrogenationpromoter selected from the group consisting of transition metalsbelonging to Groups IIIB, IVB, VB, VIB, VIIB, VIII, IB and IIB of thePeriodic Table and compounds of said transition metals.
 33. Acomposition of matter in accordance with claim 32 wherein saidrefractory inorganic carrier comprises alumina, and said at least onhydrogenation promoter is selected from the group consisting ofcompounds of Y, La, Ce, Ti, Zr, Cr, Mo, W, Mn, Re, Ni, Co and Cu.
 34. Acomposition of matter in accordance with claim 32 wherein a layer (X) ofsaid impregnated, substantially spherical alumina-containing particlesis placed below at least one layer (Y) of said catalyst particles.
 35. Acomposition of matter in accordance with claim 32 wherein a layer (X) ofsaid impregnated, substantially spherical alumina-containing particlesis placed on top of at least one layer (Y) of said catalyst particles.36. A composition of matter in accordance with claim 32 wherein theweight ratio of each layer (X) of said impregnated, substantiallyspherical alumina-containing particles to each layer (Y) of saidcatalyst particles is in the range of from about 1:100 to about 1:1. 37.A composition of matter comprising impregnated, substantially sphericalalumina-containing particles having been prepared by the processcomprising the steps of(a) impregnating (i) a starting material ofsubstantially spherical alumina-containing particles which have aninitial average particle diameter of at least about 0.05 inch, aninitial surface area, as determined by the BET method employingnitrogen, of at least 20 m² /g, an initial pore volume, as determined bymercury intrusion porosimetry, of at least about 0.1 cc/g, and aninitial content of Al₂ O₃ of at least about 80 weight-%, with (ii) asolution consisting essentially of water and dissolved ammoniumthiosulfate; and (b) heating the material obtained in step (a) at atemperature in the range of from about 500 to about 900° C. for a periodof time of at least 10 minutes, under such heating conditions as toobtain a material having a higher crush strength than said startingmaterial, wherein said crush strength is measured after exposure of eachof said materials for about 100 hours to a liquid hydrocarbon-containingstream which contains at least about 0.5 weight-% sulfur, underhydrotreating conditions at about 2250 psig total pressure, about 400psig partial pressure of steam and about 700° F.
 38. A composition ofmatter in accordance with claim 37 wherein said starting material usedin step (a) has an initial average particle size in the range of fromabout 0.1 to about 1.0 inch, an initial surface area in the range offrom about 40 to about 600 m² /g, and initial pore volume in the rangeof from about 0.2 to about 1.0 cc/g, an an initial normalized crushstrength in the range of from about 100 to about 400 lb. per inchdiameter per particle.
 39. A composition of matter in accordance withclaim 37 wherein the initial content of Na in said starting material isbelow about 2.0 weight-%, and said initial content of Al₂ O₃ in saidstarting material is in the range of from about 90 to about 99 weight-%.40. A composition of matter in accordance with claim 37 wherein theconcentration of dissolved ammonium thiosulfate in the impregnatingsolution used in step (a) is in the range of from about 0.05 to about 5mol/l, and the weight ratio of said starting material to saidimpregnating solution is in the range of from about 0.1:1 to about2.01:1.
 41. A composition of matter in accordance with claim 40 whereinsaid concentration of dissolved ammonium thiosulfate is in the range offrom about 0.1 to about 1.0 mol/l.
 42. A composition of matter inaccordance with claim 37 wherein said impregnated, substantiallyspherical alumina-containing particles obtained in step (b) have a porevolume of pores possessing a diameter of about 40-200 Angstroms in therange of from 50% to about 90% of the total pore volume, and anormalized crush strength in the range of from about 150 to about 350lb. per inch diameter per particle.
 43. A composition of matter inaccordance with claim 37 wherein said impregnated, substantiallyspherical alumina-containing particles obtained in step (b) have asurface area in the range of from about 50 to about 300 m² /g and a porevolume in the range of from about 0.3 to about 0.8 cc/g.
 44. Acomposition of matter in accordance with claim 37 wherein saidimpregnated, substantially spherical alumina-containing particles arecontained in at least one layer (X) of a fixed hydrotreating catalystbed.
 45. A composition of matter in accordance with claim 44additionally comprising at least one layer (Y) of catalyst particlescomprising a refractory inorganic carrier and at least one hydrogenationpromoter selected from the group consisting of transition metalsbelonging to Groups IIIB, IVB, VB, VIB, VIIB, VIII, IB and IIB of thePeriodic Table and compounds of said transition metals.
 46. Acomposition of matter in accordance with claim 45 wherein saidrefractory inorganic carrier comprises alumina, and said at least onehydrogenation promoter is selected from the group consisting ofcompounds of Y, La, Ce, Ti, Zr, Cr, Mo, W, Mn, Re, Ni, Co and Cu.
 47. Acomposition of matter in accordance with claim 45 wherein a layer (X) ofsaid impregnated, substantially spherical alumina-containing particlesis placed below at least one layer (Y) of said catalyst particles.
 48. Acomposition of matter in accordance with claim 45 wherein a layer (X) ofsaid impregnated, substantially spherical alumina-containing particlesis placed on top of at least one layer (Y) of said catalyst particles.49. A composition of matter in accordance with claim 45 wherein theweight ratio of each layer (X) of said impregnated, substantiallyspherical alumina-containing particles to each layer (Y) of saidcatalyst particles is in the range of from about 1:100 to about 1:1.